Information injection-pump assembly
ZEXEL
101402-0530
1014020530
ISUZU
5156014362
5156014362
Rating:
Service parts 101402-0530 INJECTION-PUMP ASSEMBLY:
1.
_
5.
AUTOM. ADVANCE MECHANIS
6.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
5-15300-103-2
12.
Open Pre:MPa(Kqf/cm2)
14.7{150}
15.
NOZZLE SET
Cross reference number
ZEXEL
101402-0530
1014020530
ISUZU
5156014362
5156014362
Zexel num
Bosch num
Firm num
Name
Calibration Data:
Adjustment conditions
Test oil
1404 Test oil ISO4113 or {SAEJ967d}
1404 Test oil ISO4113 or {SAEJ967d}
Test oil temperature
degC
40
40
45
Nozzle and nozzle holder
105780-8140
Bosch type code
EF8511/9A
Nozzle
105780-0000
Bosch type code
DN12SD12T
Nozzle holder
105780-2080
Bosch type code
EF8511/9
Opening pressure
MPa
17.2
Opening pressure
kgf/cm2
175
Injection pipe
Outer diameter - inner diameter - length (mm) mm 6-2-600
Outer diameter - inner diameter - length (mm) mm 6-2-600
Tester oil delivery pressure
kPa
157
157
157
Tester oil delivery pressure
kgf/cm2
1.6
1.6
1.6
Direction of rotation (viewed from drive side)
Right R
Right R
Injection timing adjustment
Direction of rotation (viewed from drive side)
Right R
Right R
Injection order
1-3-4-2
Pre-stroke
mm
3.6
3.55
3.65
Beginning of injection position
Drive side NO.1
Drive side NO.1
Difference between angles 1
Cal 1-3 deg. 90 89.5 90.5
Cal 1-3 deg. 90 89.5 90.5
Difference between angles 2
Cal 1-4 deg. 180 179.5 180.5
Cal 1-4 deg. 180 179.5 180.5
Difference between angles 3
Cyl.1-2 deg. 270 269.5 270.5
Cyl.1-2 deg. 270 269.5 270.5
Injection quantity adjustment
Adjusting point
A
Rack position
7.3
Pump speed
r/min
700
700
700
Average injection quantity
mm3/st.
65.5
64.4
66.6
Max. variation between cylinders
%
0
-2
2
Basic
*
Fixing the lever
*
Injection quantity adjustment_02
Adjusting point
B
Rack position
4.9+-0.5
Pump speed
r/min
300
300
300
Average injection quantity
mm3/st.
11
9.6
12.4
Max. variation between cylinders
%
0
-14
14
Fixing the rack
*
Test data Ex:
Governor adjustment
N:Pump speed
R:Rack position (mm)
(1)Target notch: K
(2)Tolerance for racks not indicated: +-0.05mm.
(3)Rack difference between N = N1 and N = N2
----------
K=10 N1=1100r/min N2=525r/min
----------
----------
K=10 N1=1100r/min N2=525r/min
----------
Speed control lever angle
F:Full speed
I:Idle
S:Stop
----------
----------
a=84deg+-5deg b=40deg+-3deg c=27deg+-5deg
----------
----------
a=84deg+-5deg b=40deg+-3deg c=27deg+-5deg
Stop lever angle
N:Pump normal
S:Stop the pump.
(1)Normal
----------
----------
a=19deg+-5deg b=53deg+-5deg
----------
----------
a=19deg+-5deg b=53deg+-5deg
Timing setting
(1)Pump vertical direction
(2)Position of gear mark 'CC' at No 1 cylinder's beginning of injection
(3)B.T.D.C.: aa
(4)-
----------
aa=18deg
----------
a=(90deg)
----------
aa=18deg
----------
a=(90deg)
Information:
Tooling and Equipment
The tools shown in Chart F, Tooling for Finding Top Center (TC) Position, are required to complete the procedure.
Table 8
Chart F
Tooling For Finding Top Center (TC) Position
Part No Description Qty Item (1)
8T-4177 Bolt, Spring Compressor 1 7
( 1 ) Refer to the nomenclature chart at the beginning of this manual for item identification.Procedure
Illustration 39 g03425683
Timing Bolt Location (35) 8T-4177 Timing Bolt (36) Timing Hole (37) Flywheel HousingNote: Depending on engine application, timing hole (36) is located at either the left front face or the right front face of the flywheel housing.
Remove plug from the timing hole (36) on the front of the flywheel housing.
Rotate the engine with four large bolts on the front of the crankshaft. Do not use the eight small bolts on the front of the crankshaft pulley as this could cause damage to the engine.
Put 8T-4177 Bolt (35) in hole. Turn the engine flywheel counterclockwise until the timing bolt engages with the threaded hole in the flywheel.Note: If the flywheel is turned beyond the point the timing bolt engages in the threaded hole, the flywheel must be turned back at least 30 degrees clockwise. Again, turn the flywheel counterclockwise until the timing bolt engages with the threaded hole. This procedure makes sure that the play is removed from the gears when number 1 piston is put on TC.
Remove the cylinder head valve cover.
Illustration 40 g03425694
Valve Cover Removed
The intake and the exhaust valves for the number 1 cylinder are fully closed if number 1 piston is on the compression stroke and the rocker arms can be moved by hand. If the rocker arms cannot be moved and the valves are slightly open, the number 1 piston is on the exhaust strike. Refer to Chart E, Crankshaft Positions for Fuel Timing Settings, to determine which cylinders can be checked/adjusted (determined by stroke position of crankshaft when timing bolt is installed).Note: When the actual stroke position is identified, and the other stroke position is desired, it is necessary to remove the timing bolt from the flywheel. Turn the flywheel counterclockwise 360 degrees, and reinstall the timing bolt.
After TC position for a particular stroke is obtained and adjustments are made, remove the timing bolt and turn the flywheel counterclockwise 360 degrees. This will put number 1 piston at TC position on the other stroke. Install timing bolt in the flywheel and complete adjustments for remaining cylinders.Removal and Installation of Unit Fuel Injectors
Table 9
Chart G
Injector Removal and Installation Tools
Part No Description Qty Item (1)
5P-0302 Injector Removal Bar 1 16
194-3542 Hex Socket Bit Driver, 5 mm 1 18
( 1 ) Refer to nomenclature chart, at the beginning of this manual for item identification.
Illustration 41 g03425701
Unit Fuel Injector (48) Bolt (49) O-RingsNote: Not all injectors use a bottom O-ring.Removal
Remove injector hold down bolt (48) .
Do not pry on the injector hold down bracket.
The tools shown in Chart F, Tooling for Finding Top Center (TC) Position, are required to complete the procedure.
Table 8
Chart F
Tooling For Finding Top Center (TC) Position
Part No Description Qty Item (1)
8T-4177 Bolt, Spring Compressor 1 7
( 1 ) Refer to the nomenclature chart at the beginning of this manual for item identification.Procedure
Illustration 39 g03425683
Timing Bolt Location (35) 8T-4177 Timing Bolt (36) Timing Hole (37) Flywheel HousingNote: Depending on engine application, timing hole (36) is located at either the left front face or the right front face of the flywheel housing.
Remove plug from the timing hole (36) on the front of the flywheel housing.
Rotate the engine with four large bolts on the front of the crankshaft. Do not use the eight small bolts on the front of the crankshaft pulley as this could cause damage to the engine.
Put 8T-4177 Bolt (35) in hole. Turn the engine flywheel counterclockwise until the timing bolt engages with the threaded hole in the flywheel.Note: If the flywheel is turned beyond the point the timing bolt engages in the threaded hole, the flywheel must be turned back at least 30 degrees clockwise. Again, turn the flywheel counterclockwise until the timing bolt engages with the threaded hole. This procedure makes sure that the play is removed from the gears when number 1 piston is put on TC.
Remove the cylinder head valve cover.
Illustration 40 g03425694
Valve Cover Removed
The intake and the exhaust valves for the number 1 cylinder are fully closed if number 1 piston is on the compression stroke and the rocker arms can be moved by hand. If the rocker arms cannot be moved and the valves are slightly open, the number 1 piston is on the exhaust strike. Refer to Chart E, Crankshaft Positions for Fuel Timing Settings, to determine which cylinders can be checked/adjusted (determined by stroke position of crankshaft when timing bolt is installed).Note: When the actual stroke position is identified, and the other stroke position is desired, it is necessary to remove the timing bolt from the flywheel. Turn the flywheel counterclockwise 360 degrees, and reinstall the timing bolt.
After TC position for a particular stroke is obtained and adjustments are made, remove the timing bolt and turn the flywheel counterclockwise 360 degrees. This will put number 1 piston at TC position on the other stroke. Install timing bolt in the flywheel and complete adjustments for remaining cylinders.Removal and Installation of Unit Fuel Injectors
Table 9
Chart G
Injector Removal and Installation Tools
Part No Description Qty Item (1)
5P-0302 Injector Removal Bar 1 16
194-3542 Hex Socket Bit Driver, 5 mm 1 18
( 1 ) Refer to nomenclature chart, at the beginning of this manual for item identification.
Illustration 41 g03425701
Unit Fuel Injector (48) Bolt (49) O-RingsNote: Not all injectors use a bottom O-ring.Removal
Remove injector hold down bolt (48) .
Do not pry on the injector hold down bracket.